Method of forming a concrete panel

ABSTRACT

A precast concrete panel and method for forming the panel are disclosed. A method of forming the panel to be used as a floor, wall, or roof structure includes positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT/US2018/040014, filed on Jun.28, 2018, which claims the benefit of Unites States Provisional PatentApplication No. 62/526,101, filed on Jun. 28, 2017, and is aContinuation-In-Part of U.S. patent application Ser. No. 14/610,475,filed on Jan. 30, 2015, which claims the benefit of U.S. ProvisionalPatent Application No. 61/934,405, filed on Jan. 31, 2014, the contentsof which are incorporated herein in their entirety by reference.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of Invention

The present general inventive concept relates to prefabricated wallstructures, and more particularly, to a precast concrete composite wallstructure and method for manufacturing a precast concrete composite wallstructure.

2. Description of the Related Art

Precast concrete wall structures are often used as a way of avoidingmore costly, time consuming, and/or labor intensive processes offabricating walls from brick or block materials, wood, metal studs, orthe like, or fabricating walls by pouring and curing concrete in situ.Generally, the manufacture of a precast concrete wall structure involvesthe use of a casting bed fabricated to form a mold for pouring andcuring concrete in the shape of a desired wall structure. The castingbed is typically oriented with the desired wall structure shapeextending in a horizontal plane. Desired non-concrete structuralfixtures may be added to the casting bed, and concrete may then bepoured into the casting bed, thereby filling the mold shape and at leastpartially surrounding the fixtures. The concrete may then be allowed tocure, thereby forming a concrete wall structure in the desired shape.Once cured, the wall structure may be removed from the casting bed, suchas for example by disassembling the casting bed from around the wallstructure. The wall structure may then be transported to a desiredlocation, where it can be stood upright along a substantially verticalplane (or other desired orientation) for use as a structural member in abuilding construction.

One prior art method for manufacturing a precast concrete wall structureis described in U.S. Pat. No. 8,491,831, issued to Buedel et al.(hereinafter “the '831 Patent”). In the method of the '831 Patent, aframe is provided having a plurality of spaced-apart wall studsinterconnecting opposing first and second wall plate members. The frameis placed within a casting bed extending along a horizontal plane, and alayer of insulating material is positioned overlaying the frame. Aplurality of insulating foam blocks are then placed above the insulatinglayer at spaced apart intervals to define void channels extendingtherebetween along the length of the casting bed. Lengths of rebar arepositioned within the channels, and concrete is poured into the castingbed, thereby filling the channels and surrounding the rebar, coveringthe insulating foam blocks, and filling the spaces between the first andsecond wall plate members and the adjacent sides of the casting bed. Theconcrete is allowed to cure, thereby forming a concrete wall structurehaving a substantially planar concrete first outer surface, a pluralityof steel-reinforced concrete “ribs” extending internally of thestructure, and a second outer surface defined by the frame structure andadjacent surface of the insulating layer. Concrete top beam and toesections are provided extending above and below the frame structure atlocations corresponding to the spaces between the first and second wallplate members and the adjacent sides of the casting bed. Thereafter, theconcrete wall structure may be removed from the casting bed, such as byremoving one or more sides of the casting bed and/or lifting the wallstructure therefrom.

In methods and apparatus for forming precast wall structures of the typedescribed above, significant problems may be encountered with regard toquality control of the finished precast wall structure. Specifically,while pouring the unfinished concrete into the casting bed describedabove, difficulty may be encountered in maintaining the desiredspaced-apart configuration of the insulating foam blocks. As theunfinished concrete flows over and around the insulating foam blocks,such blocks may be prone to flex and/or shift laterally along the layerof insulating material, and may further be prone to shift vertically dueto buoyancy of the blocks in the more dense unfinished concrete.Furthermore, depending upon the flexural strength and stiffness of thelayer of insulating material, the layer of insulating material may besubject to flexural deformation and/or failure under the weight of theunfinished concrete. The end result may be a finished wall structurewhich does not strictly conform to desired specifications.

In light of the above, an improved method for manufacturing a precastconcrete wall structure, and a precast concrete wall structuremanufactured to conform to more strict tolerances, is desired.

BRIEF SUMMARY OF THE INVENTIVE CONCEPT

The present general inventive concept, in various example embodiments,provides a precast concrete wall and a method for forming a wallstructure. In one embodiment a frame is positioned within a casting bedhaving a plurality of upright surfaces defining a generally rectangularinterior area. The frame comprises first and second spaced apart membersextending along a width dimension of the frame and a plurality of studsinterconnecting the first and second spaced apart members, the studsextending along a length dimension of the frame. A forming member ispositioned in overlying relation above the frame. The forming membercomprises a layer of insulating material defining a plurality ofintegrally-formed rectangular protrusions extending along a lengthdimension of the forming member in a parallel and spaced-apartrelationship to one another to define a plurality of rectangular-shapedchannels therebetween. Uncured concrete is placed within the casting bedand allowed to cover the forming member and substantially fill thechannels. The concrete is then allowed to cure.

In various example embodiments according to several features of thepresent general inventive concept, the frame may comprise a plurality ofmetal studs. The forming member may be oriented in relation to the framesuch that the length dimension of the forming member extends along thelength dimension of the frame. The forming member may be sized to extendfully along length and width dimensions of the frame to limit theuncured concrete from flowing between the studs of the frame. The frameand forming member may be of a sufficient width to extend adjacentopposite first and second upright surfaces of the casting bed. The frameand forming member may be positioned within the casting bed to provide afirst space between the frame first member and an associated thirdupright surface of the casting bed, wherein the uncured concrete isallowed to fill the first space to form a top beam portion of the wallstructure. The frame and forming member may further be positioned withinthe casting bed to provide a second space between the frame secondmember and an associated fourth upright surfaces of the casting bed,wherein the uncured concrete is allowed to fill the second space to forma toe portion of the wall structure.

In various example embodiments, a spacer may be positioned between theframe first member and the third upright surface of the casting bed toform the first space. The spacer may be a strip of insulating material.The spacer and the forming member may each be fabricated from a materialselected from the group consisting of expanded polystyrene, extrudedpolystyrene, and rock wool. The first and second upright surfaces of thecasting bed may define structures shaped to allow the concrete to formmatingly-shaped portions of a joint along opposite sides of the wallstructure. For example, the first upright surface may define a ridgeextending along a length thereof and the second upright surface maydefine a matingly-shaped groove extending along a length thereof.

In various example embodiments according to several features of thepresent general inventive concept, the forming member may be defined bya plurality of members arranged in side-by-side relationship. Theplurality of forming member segments may be positioned in side-by-siderelationship within the casting bed, each segment defining a portion ofthe total width of the forming member, including at least onerectangular protrusion and at least a portion of one channel. In certainembodiments, a plurality of reinforcing members may be positioned withinthe casting bed prior to placing the uncured concrete within the castingbed. For example, in certain embodiments, at least one reinforcingmember may be placed along each channel. In certain embodiments, anupper surface of the concrete may be finished. For example, a desiredtexture may be stamped or otherwise formed into the upper surface of theconcrete.

Various example embodiments of the present general inventive concept mayprovide a method of forming the panel to be used as a floor, wall, orroof structure including positioning one or more forming members withina casting bed having a plurality of upright surfaces defining agenerally rectangular interior area, the one or more forming memberscomprising an insulating material extending along a length dimension ofthe one or more forming members to define a plurality ofrectangular-shaped channels in a parallel and spaced-apart relationship,placing uncured concrete within the casting bed and allowing theconcrete to cover the one or more forming members and substantially fillthe channels, and allowing the concrete to cure.

Various example embodiments of the present general inventive concept mayprovide a panel to be used as a floor, wall, or roof structure, thepanel including a concrete portion including a face portion and aplurality of joists extending inwardly from the face portion, and aplurality of insulating portions configured between each adjacent pairof the joists.

Additional aspects and advantages of the present general inventiveconcept will be set forth in part in the description which follows, and,in part, will be obvious from the description, or may be learned bypractice of the present general inventive concept.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following example embodiments are representative of exampletechniques and structures designed to carry out the objects of thepresent general inventive concept, but the present general inventiveconcept is not limited to these example embodiments. In the accompanyingdrawings and illustrations, the sizes and relative sizes, shapes, andqualities of lines, entities, and regions may be exaggerated forclarity. A wide variety of additional embodiments will be more readilyunderstood and appreciated through the following detailed description ofthe example embodiments, with reference to the accompanying drawings inwhich:

FIG. 1 is a perspective view showing one embodiment of a precastconcrete wall constructed in accordance with several features of thepresent general inventive concept;

FIG. 2 is an exploded view of the precast concrete wall of FIG. 1;

FIG. 3 is another exploded view of the precast concrete wall of FIG. 1;

FIG. 4 is a partially exploded perspective view showing variousoperations of one embodiment of a method according to several featuresof the present general inventive concept;

FIG. 5 is a partially exploded perspective view showing other operationsof the method of FIG. 4;

FIG. 6 is a top view showing other operations of the method of FIG. 4;

FIG. 7 is a perspective view of another embodiment of a precast concretewall constructed in accordance with several features of the presentgeneral inventive concept;

FIG. 8 is a partially exploded perspective view showing variousoperations of another embodiment of a method according to severalfeatures of the present general inventive concept;

FIG. 9 is a partially exploded perspective view showing other operationsof the method of FIG. 8;

FIG. 10 is a top view showing other operations of the method of FIG. 8;

FIG. 11 illustrates a plan view of a panel according to an exampleembodiment of the present general inventive concept;

FIG. 12 illustrates a lengthwise section of the panel of FIG. 11;

FIG. 13 illustrates a crosswise section of the panel of FIG. 11;

FIG. 14 illustrates a perspective view of the panel of FIG. 11 with apartial breakout to show some of the inner components of the panel;

FIG. 15 illustrates a plan view of a panel according to another exampleembodiment of the present general inventive concept;

FIG. 16 illustrates a lengthwise section of the panel of FIG. 15;

FIG. 17 illustrates a crosswise section of the panel of FIG. 15; and

FIG. 18 illustrates a perspective view of the panel of FIG. 15 with apartial breakout to show some of the inner components of the panel.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made to certain example embodiments of the presentgeneral inventive concept which are illustrated in the accompanyingdrawings and illustrations. The example embodiments are described hereinin order to explain the present general inventive concept by referringto the figures. The following detailed description is provided to assistthe reader in gaining a comprehensive understanding of the structuresand fabrication techniques described herein. Accordingly, variouschanges, modification, and equivalents of the structures and fabricationtechniques described herein will be suggested to those of ordinary skillin the art. The progression of fabrication operations described aremerely examples, however, and the sequence type of operations is notlimited to that set forth herein and may be changed as is known in theart, with the exception of operations necessarily occurring in a certainorder. Also, description of well-known functions and constructions maybe omitted for increased clarity and conciseness.

Note that spatially relative terms, such as “up,” “down,” “right,”“left,” “beneath,” “below,” “lower,” “above,” “upper” and the like, maybe used herein for ease of description to describe one element orfeature's relationship to another element(s) or feature(s) asillustrated in the figures. Spatially relative terms are intended toencompass different orientations of the device in use or operation inaddition to the orientation depicted in the figures. For example, if thedevice in the figures is turned over or rotated, elements described as“below” or “beneath” other elements or features would then be oriented“above” the other elements or features. Thus, the exemplary term “below”can encompass both an orientation of above and below. The device may beotherwise oriented (rotated 90 degrees or at other orientations) and thespatially relative descriptors used herein interpreted accordingly.

In accordance with several features of the present general inventiveconcept, a precast concrete wall structure and method for manufacturinga precast concrete wall structure are disclosed herein and in theaccompanying figures. With reference to the accompanying figures, andwith particular reference to FIGS. 1-3, in one embodiment, a wallstructure 10 is provided which includes an outer concrete face 12defining an outer surface 36 forming an exterior surface of the wallstructure 10, and an inner surface 18 defining a plurality ofinwardly-facing ribs 14. In the illustrated embodiment, each of the ribs14 is of a substantially rectangular cross-section and extendssubstantially vertically along the inner surface 18 of the concrete face12 in substantially parallel-planar, spaced apart relation to the otherribs. In the illustrated embodiment, the concrete face 12 defineselongated top beam 38 and toe 40 portions extending inwardly from theinner surface 18 along respective upper 42 and lower 44 ends of theconcrete face 12, in an orientation substantially perpendicular to theribs 14.

In several embodiments, the concrete face 12 is fabricated from areinforced concrete material, of the type having a plurality ofreinforcing members embedded in a cement-based concrete material. Forexample, in the present embodiment, a plurality of elongated steelreinforcing members are provided within the concrete face 12, extendingsubstantially parallel to the inner and outer surfaces 18, 36 thereof.More specifically, in the present embodiment, a plurality of elongatedsteel members are provided, each member extending within and along arespective rib 14 of the concrete face 12, thereby strengthening theconcrete face 12 and resisting flexure of the concrete face 12. Incertain embodiments, additional reinforcement in the form of wire meshor fiber materials may be provided within and along the concrete face12.

It will be recognized that the above-discussed reinforcement againstflexure of the concrete face 12 may be useful in various applications ofthe wall structure 10, such as for example use of the wall structure 10in forming a basement or other below-ground or partially below-groundstructure, or in forming a retaining wall structure. However, it willfurther be understood that the reinforcing members may be provided atother locations within the concrete face 12 without departing from thespirit and scope of the present general inventive concept. For example,in other embodiments, one or more reinforcing members may be providedslightly interior to the outer surface 36 of the concrete face 12 toreinforce the concrete face against flexure. Such reinforcement may beuseful in other applications of the wall structure 10, such as forexample use of the wall structure 10 in forming portion of anabove-ground or partially above-ground structure, such as anabove-ground or partially above-ground residential, commercial, orindustrial building. Additional reinforcement may also be providedextending within the top beam 38 or toe 40 to provide strength andreinforcement to those portions of the wall structure 10.

A substantially planar forming member 16 is provided extending along theinner surface 18 of the concrete face 12. The forming member 16 definesa plurality of outwardly-extending rectangular protrusions 20 sized andshaped to be received in mating engagement between each of the ribs 14.In several embodiments, the forming member 16 is constructed from amaterial that allows the forming member 16 to provide moistureresistance and vapor permeability to the wall structure 10 and/or todecrease the overall thermal conductivity of the wall structure 10. Forexample, in several embodiments, the forming member 16 is fabricatedfrom an insulating material, such as for example expanded polystyrene(EPS), extruded polystyrene (XPS), rockwool, or other such material. Ina preferred embodiment, the forming member 16 is both resistant tomoisture and thermally insulating.

Referring to FIGS. 2 and 3, in one embodiment, the forming member 16comprises a layer of EPS material having a plurality ofintegrally-formed protrusions 20 extending along an outer surface 32thereof. The protrusions 20 are generally rectangular in shape andextend in a parallel and spaced-apart relationship to one another todefine a plurality of rectangular-shaped channels 30 therebetween. Aswill be discussed in greater detail below, the channels 30 provide moldforms for forming the ribs 14 of the concrete face 12 during manufactureof the wall structure 10. Hence, each rib 14 of the concrete face 12 ismated to, and is received within, a respective channel 30 of the formingmember 16, and each protrusion 20 is received between and adjacentcorresponding ribs 14 of the concrete face 12. It will be understoodthat the specific dimensions of the various elements of the formingmember 16 may vary depending upon the desired characteristics of thefinished wall structure 10. For example, in one embodiment, therectangular protrusions 20 may be approximately sixteen inches wide,while the channels 30 may be approximately 3.5 inches wide andapproximately 5.5 inches deep. Accordingly, each mating rib 14 may beapproximately 3.5 inches wide and approximately 5.5 inches deep, andeach rib 14 may be spaced approximately 19.5 inches apart,centerline-to-centerline. In this embodiment, the portions of theforming member 16 extending between the rectangular protrusions 20 maybe approximately 1.5 inches thick. However, it will be understood thatthe present general inventive concept is not limited to such dimensionalrestrictions.

In several embodiments, the forming member 16 terminates at a lower edgeof the top beam 38 and at an upper edge of the toe 40. In certain ofthese embodiments, the top beam 38 and toe 40 each extend inwardly to atleast partially surround upper and lower ends, respectively, of theforming member 16. In some embodiments, the top beam 38 and toe 40portions of the concrete face 12 may each extend inwardly to completelysurround the upper and lower ends, respectively, of the forming member16. In other words, the top beam 38 and toe 40 portions of the concreteface 12 may each extend inwardly to terminate substantially flush withan inner surface 24 of the forming member 16. In other embodiments, thetop beam 38 and toe 40 portions of the concrete face 12 may terminateoutwardly of the forming member inner surface 24, or in other words, mayterminate short of the inner surface 24 of the forming member 16. Incertain of these embodiments, at least one insulating member 46 may beprovided along an inner surface of the top beam 38 and/or the toe 40.

In several embodiments, the forming member 16 defines a relativelysmooth inner surface 24 opposite the outwardly-extending protrusions 20.The inner surface 24 of the forming member 16 defines an interiorsurface of the wall structure 10. In several embodiments, a stud frame22 is secured along the inner surface 24 of the forming member 16 toprovide an attachment means for additional structures which may beuseful in conjunction with the wall structure 10, i.e., drywall or otherinterior wall sheathing, additional insulation, plumbing or electricalfixtures, or the like. In the illustrated embodiment, the stud frame 22comprises generally first and second spaced apart members 26 extendingalong opposite upper and lower edges 48, 50 of the forming member 16.The upper and lower members 26 are interconnected by a plurality ofstuds 28 extending perpendicular to the members 26 in parallel, spacedapart relation to one another. The stud frame 22 may be fabricated fromany of a variety of conventional materials commonly used in theconstruction of building framing without departing from the spirit andscope of the present general inventive concept. However, in a preferredembodiment, the stud frame 22 is of a metal construction and comprisesgenerally first and second spaced apart metal tracks as the upper andlower members 26 having metal studs 28 extending therebetween.

In the illustrated embodiment, the various studs 28 of the stud frame 22extend uniformly between the upper and lower members 26 at evenly-spacedlocations along the width of the stud frame 22. However, it will berecognized that the configuration of the stud frame 22 may vary in orderto allow the stud frame 22 to provide any of numerous desirable featurescommonly associated with framed building construction. For example, inseveral embodiments, the upper and lower members 26 of the stud frame 22may comprise double cap or sole members of the type commonly found intraditional building framing. The stud frame 22 may further define dooror window frames, with associated cripple studs, top beam members, etc.,of the type commonly found in building framing. It will be recognizedthat, in such embodiments, corresponding through openings may be definedin the concrete face 12 and forming member 16 to accommodate such doorand window frames. Numerous such configurations will be recognized byone of skill in the art and may be used without departing from thespirit and scope of the present general inventive concept.

In several embodiments, opposite first and second sides 52, 54 of thewall structure 10 define suitable structures or mating surfaces to allowthe wall structure 10 to be joined along its first or second side 52, 54with an adjacent wall structure 10 to form a continuous wall. Forexample, in several embodiments, suitable fasteners are embedded alongthe first or second sides 52, 54 of the wall. In other embodiments, thefirst and second sides 52, 54 of the wall structure 10 define matingjoint surfaces adapted to form a joint with an adjacent wall structure10. With reference to FIGS. 1-3, in the illustrated embodiment, thefirst and second sides 52, 54 of the wall structure definematingly-shaped female and male lap joints, respectively, extendingalong respective lengths of the first and second sides 52, 54. Morespecifically, in the illustrated embodiment, the portion of the concreteface 12 along the first side 52 defines a female portion of a lap joint56, while the portion of the concrete face 12 along the second side 54defines a male portion of a lap joint 58. The female and male lap jointportions 56, 58 are matingly-shaped, such that each male portion 56 maymate with a corresponding female portion 58 of an adjacent wallstructure 10, thereby joining adjacent wall structures in side-by-siderelationship with one another. Those of skill in the art will recognizeother suitable shapes which may be used in forming the mating surfacesof the first and second sides 52, 54 of the wall structure withoutdeparting from the spirit and scope of the present general inventiveconcept.

In accordance with several additional features of the present generalinventive concept, a method of manufacturing a precast concrete wallstructure is also disclosed herein and in the accompanying figures.Various operations according to one embodiment of a method ofmanufacturing a precast concrete wall structure, or “method,” may beunderstood by reference to the illustrations depicted in FIGS. 4-6 andthe description herein. With reference to FIGS. 4-6, in one embodiment,a casting bed 60 is provided having a plurality of surfaces 62, 64 fordefining a generally rectangular interior area 66 correspondinggenerally to a desired overall shape of the finished wall structure 10.In the embodiment of FIG. 4, the casting bed 60 includes generally firstand second elongated side rails 67, 68 arranged in a parallel,spaced-apart relationship, with first and second elongated gate members70, 72 extending therebetween in parallel, spaced-apart relationshipwith one another, and in perpendicular relationship with the first andsecond side rails 67, 68. Each side rail 67, 68 defines an interiorplanar surface 62 facing an interior planar surface 62 of the oppositeside rail 67, 68, and likewise, each gate member 70, 72 defines aninterior planar surface 64 facing an interior planar surface 64 of theopposite gate member. Thus, the planar surfaces 62, 64 cooperate todefine a substantially rectangular interior area 66 therebetween. Thevarious side rails 67, 68 and gate members 70, 72 may be assembled andplaced along a substantially flat, level support surface, such as atable or the floor, with respective lower edges of the interior planarsurfaces 62, 64 substantially flush with the support surface, therebysubstantially closing the lower end of the rectangular interior area 66.Thus, the interior area 66 forms a substantially planar, rectangularmold having an interior shape substantially corresponding to a desiredoverall shape of the finished wall structure 10.

In several embodiments, one or more of the interior planar surfaces 62,64 of the casting bed may optionally define shapes suitable for formingthe above-discussed fasteners and/or joint portions of the wallstructure 10. For example, in one embodiment, the interior surface 64 ofthe second gate member 72 defines a lip 80 extending outwardly therefromalong a length thereof, while the interior surface 64 of the oppositefirst gate member 70 defines a groove 82 extending along a lengththereof. The lip and groove 80, 82 provide mold surfaces of the castingbed 60 suitable to form the above-discussed matingly-shaped jointportions 56, 58 along opposite side surfaces of the finished wallstructure 10. In other embodiments, suitable cutouts are provided alonginterior surfaces 62, 64 to allow the placement of fasteners along theinterior surfaces, protruding into the interior area 66 of the castingbed 60.

With reference to FIG. 4, a stud frame 22 may be provided and positionedwithin the casting bed 60 to extend along the support surface. Inseveral embodiments, the casting bed 60 is sized such that the frame 22extends substantially fully between opposite interior surfaces 64 of theof the gate members 70, 72 and/or between opposite interior surfaces 62of the side rails 67, 68. In other embodiments, the frame 22 may besized to extend only partially between opposite interior surfaces 62 ofthe of the side rails 67, 68 and/or between opposite interior surfaces64 of the gate members 70, 72. In such embodiments, the frame 22 may bepositioned between the opposite interior surfaces 62, 64 of the siderails 67, 68 and gate members 70, 72 so as to provide space between theframe 22 and the interior surfaces 62, 64 for formation of the top beam38 and toe 40 portions of the wall structure 10 discussed above. In someembodiments, a suitable spacer may optionally be positioned between theframe 22 and at least one interior surface 62, 64 of the casting bed 60to assist in positioning the frame 22 at a desired location along thesupport surface of the casting bed 60. In some embodiments, the spacermay be designed to form a portion of the top beam 38 or toe 40 of thewall structure 10 upon completion of the wall structure 10 as describedhereinbelow. For example, in the illustrated embodiment, theabove-discussed insulating member 46 serves as an elongated spacerduring manufacture of the wall structure 10. The insulating member(hereinafter, “spacer”) 46 comprises a strip of insulating extrudedpolystyrene (XPS) approximately one inch in thickness. The spacer 46 ispositioned between the upper member 74 of the stud frame 22 and anadjacent interior surface 62 of the casting bed 60. Upon completion ofthe present embodiment of the method as further described hereinbelow,the spacer 46 forms an interior portion of the top beam 38 of the wallstructure 10 and provides a layer of insulation and moisture resistanceto the top beam portion 38 of the wall structure 10.

With reference to FIG. 5, upon positioning the frame 22 within thecasting bed 60, a forming member 16 may then be positioned in overlyingrelationship above the stud frame 22, with the rectangular protrusions20 of the forming member 16 protruding generally upwardly away from theframe 22. In several embodiments, the forming member 16 may be sized toextend along the frame 22 to span the length and width of the frame 22,thereby cooperating with the support surface of the casting bed toencapsulate the spaces between each of the studs 28 of the frame 22 andto limit fluid communication between the spaces between the studs 28 andthe remainder of the interior area 66 of the casting bed 60. In apreferred embodiment, the forming member 16 is positioned such that theprotrusions 20 extend generally parallel to the studs 28 of the frame22. However, it will be recognized that the protrusions 20 may bepositioned non-parallel to the studs 28 without departing from thespirit and scope of the present general inventive concept.

As discussed above, the forming member 16 includes a plurality ofrectangular protrusions 20 extending in parallel and spaced-apartrelationship to define a plurality of parallel channels 30 extendingalong a width dimension of the forming member 16. In one embodiment, theforming member 16 is defined by a single, unitary member. In otherembodiments, the forming member 16 is defined by a plurality of membersarranged in side-by-side relationship to form the forming member 16. Forexample, in one embodiment, a plurality of forming member segments areprovided, with each segment defining a portion of the total length ofthe forming member 16, including one or more of the rectangularprotrusions 20 and one or more channels 30. In this embodiment, aplurality of forming member segments are provided and arranged inside-by-side relationship to form the complete forming member 16,including the desired number of rectangular protrusions 20 and channels30 interposed therebetween. The forming member segments may be securedto one another via suitable fasteners of the type known to one of skillin the art.

With further reference to FIG. 5, following placement of the formingmember 16 in the casting bed 60, a plurality of reinforcing members 76are optionally positioned within the casting bed 60 at locations eitherabove the forming member 16 or between the protrusions 20, within thechannels 30. As discussed above, the reinforcing members 76 may be ofthe type commonly used to reinforce concrete, such as for example rebarsegments, wire mesh, or the like. The reinforcing members 76 may besupported centrally along each of the channels 30 or may be supportedfrom contact with the surfaces of the forming member 16 using suitablespacers of the type known to one of skill in the art.

As shown in FIG. 6, following placement of the forming member 16 andoptional placement of the reinforcing members 76, uncured, flowableconcrete 78 is placed within the casting bed 60. The concrete 78 isallowed to fill each of the channels 30 and any voids between the sidewalls 62, 64 of the casting bed 60 and the frame 22 and forming member16. For example, as discussed above, in one embodiment, suitable spacesare left between each of the upper and lower members 26 of the frame 22and the adjacent walls 62, 64 of the casting bed 60 for formation of thetop beam 38 and toe 40 portions of the wall structure 10 along outeredges of the wall structure adjacent the upper and lower members 26 ofthe frame 22. In such embodiments, the flowable concrete 78 is allowedto fill such spaces, thereby forming the top beam 38 and toe 40 portionsof the wall structure 10. However, it will be recognized that, becausethe forming member 16 serves to encapsulate the spaces between each ofthe studs 28 of the frame 22, the forming member 16 limits the concretefrom flowing into the spaces between each of the studs 28.

In certain embodiments, an upper surface of the uncured concrete 78 isfinished to a substantially level surface. In other embodiments,self-leveling concrete is employed, such that finishing the uppersurface subsequent to pouring the concrete 78 into the casting bed 60 isnot necessary. In still other embodiments, and in particular in certainembodiments in which the outer surface of the concrete face 12 is to beexposed, such as for example when the wall structure 10 is to be used inan above-ground or partially above-ground setting, the uncured concrete78 may be finished to a desired texture via tamping, troweling,brushing, stamping, or other techniques known in the art. Thereafter,the concrete is allowed to at least partially cure to form a rigidconcrete face 12, thereby forming the finished wall structure 10. Thewall structure 10 may then be removed from the casting bed 60 by meansknown in the art, such as for example by lifting the wall structure 10and/or by disassembling, or partially disassembling, the casting bed 60.In still other embodiments, following curing of the concrete to form therigid concrete face 12, the exterior surface of the concrete face 12 isfurther finished to a desired surface or texture. For example, in oneembodiment, following curing of the concrete, an additional applicationof material, such as for example paint, stain, wood or brick veneer,plaster, or the like, is applied to the outer surface of the concreteface 12. In another embodiment, following curing of the concrete, theouter surface of the concrete face 12 is abraded, such as for example bysanding, sandblasting, or the like, to a desired finish.

FIGS. 7-10 illustrate another embodiment of a wall structure 10 a, aswell as various operations of another embodiment of a method accordingto several features of the present general inventive concept. In theembodiment of FIGS. 7-10, a wall structure 10 a is formed which may beused in the construction of a wall which extends upwards to providemultiple floors in height. With reference to FIG. 7, in one embodiment,the wall structure 10 a includes generally a first stud frame 22 a andcorresponding forming member 16 a arranged in parallel-planar, overlyingrelationship with one another, and a second stud frame 22 b andcorresponding forming member 16 b arranged in parallel-planar, overlyingrelationship with one another. The first stud frame 22 a andcorresponding forming member 16 a are arranged in a spaced-apart,end-to-end configuration in relation to the second stud frame 22 b andcorresponding forming member 16 b. Thus, the outer concrete face 12 aextends around an upper end 84 of the first stud frame 22 a andcorresponding forming member 16 a to form a top beam 38 a, around alower end 86 of the second stud frame 22 b and corresponding formingmember 16 b to form a toe 40 a, and between the two sets of stud framesand forming members to form an intermediary beam 88.

In the illustrated embodiment, the first and second sets of stud framesand forming members 16 a, 22 a and 16 b, 22 b are arranged in anend-to-end vertical configuration, such that the wall structure 10 a mayprovide multiple floors in height. In such an embodiment, it will berecognized that the intermediary beam 88 may serve to provide a locationfor anchoring additional structures suitable to form an elevatedceiling, floor structure, or the like. However, it will further beunderstood that other configurations for the first and second sets ofstud frames and forming members 16 a, 22 a and 16 b, 22 b may beutilized without departing from the spirit and scope of the presentgeneral inventive concept. For example, in another embodiment (notshown), the first and second sets of stud frames and forming members arearranged in a horizontal, side-by-side configuration, such that theconcrete face forms a top beam along upper ends of both sets of studframes and forming members, a toe along lower ends of both sets of studframes and forming members, and a vertical stud extending between thetwo sets of stud frames and forming members. It will further berecognized that multiple sets of stud frames and forming members may beprovided in side-by-side arrangement, end-to-end arrangement, or acombination thereof, without departing from the spirit and scope of thepresent general inventive concept.

With reference to FIGS. 8-10, in one embodiment of the method, a castingbed 60 a is provided having a plurality of surfaces 62 a, 64 a fordefining a generally rectangular interior area 66 a correspondinggenerally to a desired overall shape of the finished wall structure 10a. Of note in the present illustrated embodiment, the depicted castingbed 60 a does not include the above-discussed structures suitable forformation of the joint. Thus, each of the interior surfaces 62 a, 64 aof the casting bed 60 a is relatively smooth and upright.

As shown in FIG. 8, in one embodiment of the method, the above-discussedfirst and second stud frames 22 a, 22 b may be provided and positionedwithin the casting bed 60 a in a parallel-planar relationship along thesupport surface, and in an end-to-end, or side-by-side, and spaced-apartrelationship with one another. In the illustrated embodiment, thecasting bed 60 a is sized such that the first and second frames 22 a, 22b each extend substantially fully between opposite interior sidesurfaces 64 a of the of casting bed 60 a. However, the distance betweenopposite interior end surfaces 62 a of the casting bed 60 a is such thatthe frames 22 a, 22 b extend between the end surfaces 62 a in theirend-to-end and spaced-apart configuration and allow sufficient spacefrom the end surfaces 62 a to form the above-discussed top beam 38 a andtoe 40 a. It will be noted that, in the illustrated embodiment, theabove-discussed spacer between the frames and the interior surfaces ofthe casting bed is not provided. However, one or more such spacerssimilar to the one described above may be provided without departingfrom the spirit and scope of the present general inventive concept.

With reference to FIG. 9, upon positioning the first frame 22 a withinthe casting bed 60 a, the first forming member 16 a may then bepositioned in overlying relationship above the first frame 22 a, withthe rectangular protrusions 20 of the first forming member 16 aprotruding generally upwardly away from the first frame 22 a. Likewise,upon positioning the second frame 22 b within the casting bed 60 a, thesecond forming member 16 b may then be positioned in overlyingrelationship above the second frame 22 b, with the rectangularprotrusions 20 of the second forming member 16 b protruding generallyupwardly away from the second frame 22 b. Similar to the above-discussedembodiment, the forming members 16 a, 16 b may be sized to extend alongtheir respective frames 22 a, 22 b to span the length and width of theframe, thereby cooperating with the support surface of the casting bed60 a to encapsulate the spaces between each of the studs 28 of therespective frame 22 a, 22 b and to limit fluid communication between thespaces between the studs 28 and the remainder of the interior area 66 aof the casting bed 60 a. Furthermore, as discussed above, each of theforming members 16 a, 16 b may be defined by a single, unitary member,or may be defined by a plurality of members arranged in side-by-siderelationship to form the forming member.

With further reference to FIG. 9, following placement of the formingmembers 16 a, 16 b in the casting bed 60 a, a plurality of reinforcingmembers 76 a are optionally positioned within the casting bed 60 a atlocations either along or between the forming members 16 a, 16 b. In theillustrated embodiment, the reinforcing members 76 a are distributedgenerally along the various channels 30 of the forming members 16 a, 16b, along the space between the two forming members 16 a, 16 b andbetween the two frames 22 a, 22 b, and along the spaces between each ofthe forming members 16 a, 16 b and their respective adjacent interiorend surfaces 62 a of the casting bed 60 a. As shown in FIG. 10,following placement of the reinforcing members 76 a, uncured, flowableconcrete 78 a is placed within the casting bed 60 a. The concrete 78 ais allowed to fill each of the channels 30 of the forming members 16 a,16 b, the space between the two forming members 16 a, 16 b and betweenthe two frames 22 a, 22 b, and any voids between the side walls 62 a, 64a of the casting bed 60 a and the frames 22 a, 22 b and forming members16 a, 16 b. Thus, the flowable concrete 78 is allowed to form the topbeam 38 a, toe 40 a, and intermediate beam 88 portions of the wallstructure 10.

Similar to the above-discussed method, in certain embodiments, an uppersurface of the uncured concrete 78 a is finished to a desired surface.For example, in certain embodiments, the upper surface of the uncuredconcrete 78 a is finished to a substantially level surface. In stillother embodiments, the uncured concrete 78 a is finished to a desiredtexture via techniques known in the art, such as for example painting,staining, tamping, troweling, brushing, stamping, or the application ofveneers or other such surface coverings. The concrete is allowed to atleast partially cure to form the rigid concrete face 12 a, therebyforming the finished wall structure 10 a. The wall structure 10 a maythen be removed from the casting bed 60 a by means known in the art,such as for example by lifting the wall structure 10 a and/or bydisassembling, or partially disassembling, the casting bed 60 a.

From the foregoing description, it will be recognized by one skilled inthe art that a precast concrete wall structure and method formanufacturing a precast concrete wall structure are provided hereinwhich allow significant improvement over prior art methods andapparatus. For example, it will be recognized that, by forming theforming layer 16 from an insulating material, such as for exampleexpanded polystyrene (EPS), extruded polystyrene (XPS), rockwool, orother such material, the forming layer 16 serves to increase theinsulating properties of the wall structure 10, thereby allowing thewall structure 10 to be used in applications in which an insulating wallis desired absent the need to add further insulating material to thewall structure 10. It will further be recognized that the amount ofthermal resistance provided by the materials of the forming layer 16are, at least in part, a function of the average thickness per unit areaof forming layer material along the surface of the wall structure 10.Accordingly, it will be recognized that the specific dimensions of theforming layer 16, i.e., the thickness, width, and spacing of theprotrusions 20 and of the portions of the forming layer 16 between theprotrusions 20, may vary in order to achieve a desired thermalresistance of the wall structure 10, while also maintaining structuralintegrity of the wall structure 10 and suitability of the wall structure10 for use in a specific application.

It will be recognized that, through application of the method disclosedherein, a precast concrete wall structure may be made having significantadvantages over conventional poured-in-place concrete wall structures.Through application of the method disclosed herein, a precast concretewall structure weighing approximately 50 lbs. per square foot may beproduced, wherein a poured-in-place concrete structure of the samethickness would weigh approximately 126 lbs. per square foot. Thus,significant reductions in material cost and associated transportationexpense may be achieved. Furthermore, it will be recognized that theprecast concrete wall structure provided herein includes a frame havingstuds pre-installed along one surface thereof, thereby saving theexpense and labor associated with installing these fixtures at thedesired finished location for the wall structure. In severalembodiments, the EPS and XPS materials forming the wall structure may berecycled into other products following their use in the wall structure,and in certain embodiments, scrap EPS materials may be used to form theforming member. Furthermore, it will be understood that the reinforcingmembers may be formed from recycled materials, i.e., recycled rebar,without departing from the spirit and scope of the present generalinventive concept.

Various example embodiments of the present general inventive concept mayalso be used to produce floor and/or roof structures such as floorpanels, roof panels, deck panels, etc. FIGS. 11-18 illustrate variousfeatures and configurations of two example embodiments of such panels.For the sake of simplicity in these descriptions, the structures may bereferred to simply as panels, but it is understood that the structurescan be utilized as floor panels, deck panels, roof panels, etc., or anyother number of similar structures, including wall panels.

FIG. 11 illustrates a plan view of a panel according to an exampleembodiment of the present general inventive concept, FIG. 12 illustratesa lengthwise section of the panel of FIG. 11, FIG. 13 illustrates acrosswise section of the panel of FIG. 11, and FIG. 14 illustrates aperspective view of the panel of FIG. 11 with a partial breakout to showsome of the inner components of the panel. The example embodimentillustrated in FIGS. 11-14 is a panel with no soffit. As can be seenfrom FIGS. 11-14, the panel 100 is similar to the example embodimentsillustrated in FIGS. 1-10, but is formed without a stud frame. Asillustrated in the plan view of FIG. 11, the panel 100 has bearingclosures 104 provided across the entirety of both respective ends of thepanel 100. These bearing closures 104 are analogous to the top beam 38and toe 40 illustrated in FIGS. 1-3. An intermediary beam 108, which maybe referred to herein as a web stiffener, is provided across the panel100 at approximately the center point of the panel 100. In variousexample embodiments of the present general inventive concept, the panel100 may be formed with a length of 10 feet from an end of the panel 100to a center of the intermediary beam 108, but placement of such a beamin other example embodiments may vary. As a floor or roof panel islikely to encounter more forces acting in a direction perpendicular to aface of the panel 100, such intermediary beams 108 may be more necessarythan would be needed for a wall panel. The web stiffener or intermediarybeam 108 may be provided with a reinforcement component such as rebar,prestressing strand, wire, etc., to produce increased structural supportagainst flexing or other undesired forces. Although the exampleembodiment in FIG. 11 illustrates one intermediary beam 108, or webstiffener, proximate the center of the panel 100, other exampleembodiments of the present general inventive concept may include no ormore intermediary beams, and/or may vary in the placement of thebeam(s). The longitudinal section of the panel 100 illustrated in FIG.12 shows the bearing closures 104, as well as the web stiffener 108,which in various example embodiments may each have a width ofapproximately 4 inches. FIG. 12 also shows the upper surface of thepanel having a face 112 which may have, for example, a thickness ofapproximately two inches. Similar to the previously described exampleembodiments, the face, bearing closures, and web stiffener are formed ofconcrete. However, it is understood that different example embodimentsmay include more or fewer components, and may have different dimensions,than those illustrated in FIGS. 11-14 without departing from the scopeof the present general inventive concept.

As illustrated in FIG. 12, the web stiffener 108 of this exampleembodiment does not extend as far from the face 112 of the panel 100 asdo the bearing closures 104 formed at each end of the panel 104. Thisconfiguration may be formed by the forming member 120 used in theconstruction of the panel 100, in which the forming member defines achannel in which the web stiffener 108 is formed. As discussed herein,the forming member 120 may be of single piece construction, or mayinclude several separately formed components depending upon the desiredconfiguration and features. FIG. 12 also illustrates lifting devices 116such as lift hooks that may be formed to aid in the lifting andotherwise moving, installation, etc., of the panel 100. The liftingdevices may vary according to different example embodiments and/ordesired usage, and may be simply omitted in various example embodimentsof the present general inventive concept.

As illustrated in FIG. 13, the forming member 120 defines a plurality ofparallel and evenly spaced channels in which concrete joists 124 areformed. In various example embodiments of the present general inventiveconcept, the forming member 120 may be constructed of any of a host oftypes of insulation, but are preferably structurally robust enough forconcreted to be poured over without being deformed. As illustrated inFIG. 13, every other concrete joist 124 is provided with a nailer strip128 on the face thereof, such as, for example, a P.T. 2×4 nailer strip,for attaching other surface fixtures/bodies/members to a bottom face ofthe panel. In various example embodiments of the present generalinventive concept, wooden 2×4's may be employed as the nailer strips128. It is understood that “upper” and “bottom” surface terms are usedrelative to the orientation illustrated in FIGS. 11-14, and the panel100 may be used in different orientations such as, for example, thediscussed “upper” surface facing a bottom of an installation. To providethe nailer strips 128 to the panel, the insulation forming member 120may actually include a number of separately formed components. Forexample, to produce the example embodiment illustrated in FIG. 13, fourseparate forming member 120 components may be employed. Each of the fourseparate forming members 120 may define a central longitudinal channelin which an entire concrete joist 124 may be formed, and a centrallydefined cross channel in which the previously described web stiffener108 may be formed. By alternating these forming member 120 componentswith nailer strips 128, and arranging the components so that all are inflush contact with one another, the regularly spaced and formed concretejoists 124 may be formed in the channels defined therein. In variousexample embodiments, the nailer strips 128 may be formed integrally withthe insulation components of the forming member 120 to provide a singlepiece construct. As indicated in FIG. 14, each of the concrete joistsmay have reinforcing members 76 such as, for example, rebar,prestressing strand, wire, etc., formed therein to provide enhancedstructural support. Multiple strands of rebar or other structuralcomponents may be employed in each web location, and depth placement ofthe structural components may vary according to various exampleembodiments of the present general inventive concept. As illustrated inFIG. 14, rebar has been placed in each of the channels defined by theforming member(s), in which the concrete joists are formed, to act asthe reinforcing members 76.

As illustrated in FIG. 13, grout keyways 132 may be formed on therespective outer surfaces of the outermost concrete joists 124 toimprove the connection of panels 100 to one another. The grout keyways132 may be formed by protusions in the casting bed in which these panels100 are formed. In the example embodiment illustrated in FIG. 13, thegrout keyways 132 may be approximately 2 inches wide, and may start at apoint approximately 3 inches from the upper surface of the panel. Asalso illustrated in FIG. 13, the width of the portion of the outermostconcrete joists 124 between the grout keyway 132 and the upper surfacemay be approximately ½ inch smaller than width of the concrete joist 124below the grout keyway 132. Such an indention may also be formed in thecasting bed, and may be formed by the same protrusions respectivelyforming the grout keyways 132.

The forming of a panel such as that illustrated in FIGS. 11-14 may invarious example embodiments be very similar to the process previouslydescribed in relation to FIGS. 4-6, albeit without the inclusion of astud frame. A casting bed defining the desired length, width, andthickness of the frame may be constructed and placed upon a flat formingsurface. The inner surface of the lengthwise members of the casting bedmay have formed thereon the protrusion(s) to form the grout keyways 132of the panel, as well as the outer indentation of the upper part of theoutermost concrete joists. In various example embodiments, a nailerstrip 128 may be placed on the flat surface inside the casting bed andflush against one lengthwise member of the casting bed. Space may beleft at either end of the nailer strip 128 to form the bearing closures104. Such spacing may be actuated by other methods rather than simplyleaving an empty space, in order to prevent the forming members 120 frommovement during fabrication of the panel 100. Then a forming member 120may be placed flush alongside the nailer strip 128, and the process maybe repeated until the casting bed is filled. After the forming members120 are placed, rebar or other structural components may be placed inthe respective grooves or channels to act as reinforcing members 76 inthe spaces that will form the concrete joists 124. The channels may bedefined such that the concrete joists 124 will be parallel and evenlyspaced across the width of the panel 100, and running end to end to thebearing closures 104. The insulation used in the forming members 120 maybe one of the types mentioned in the previously described embodiments ofthe present general inventive concept. After placement of all theforming members 120 and structural reinforcements, uncured, flowableconcrete is placed within the casting bed. The concrete is allowed tofill each of the channels of the forming members 120, the space at thelongitudinal ends of the forming members 120, and to form the face 112or upper surface over the forming members 120 to the desired thickness.The upper surface of the uncured concrete may be finished to a desiredsurface as described in the previous example embodiments of the presentgeneral inventive concept. Upon removal from the casting bed, or uponremoval of the casting bed, the panel 100 will have the form illustratedin FIGS. 11-14.

FIG. 15 illustrates a plan view of a panel according to another exampleembodiment of the present general inventive concept, FIG. 16 illustratesa lengthwise section of the panel of FIG. 15, FIG. 17 illustrates acrosswise section of the panel of FIG. 15, and FIG. 18 illustrates aperspective view of the panel of FIG. 15 with a partial breakout to showsome of the inner components of the panel. The example embodiment panel136 illustrated in FIGS. 15-18 is similar to the example embodimentillustrated in FIGS. 11-14, except that a concrete soffit 140 isprovided to the panel 136. Thus, rather than having a lower surfaceformed of insulation and nailer strips, the lower surface will be formeduniformly with concrete that may be the same as the upper surface orface 112 of the panel 136. To form such a panel 136, in which insulationportions 144 acting as forming members are “floating” inside theconcrete wall, in various example embodiments an approximately 2 inchlayer of concrete is poured into the casting bed before the formingmembers or insulation portions 144 of the panel 136 are placed therein.This lower sheet of concrete will form the soffit 140 of the panel 136.After the lower sheet of concrete has hardened to a desired state so asto support the weight of the forming members or insulation portions 144and concrete poured thereon, the insulative forming members 144 areplaced at regular intervals in the casting bed on top of the soffit 140such that channels are defined therebetween in which concrete joists 124will be formed. As in the example embodiment illustrated in FIGS. 11-14,space may be left at each end for the bearing closures 104, andapproximately 4 inch spaces may be left between each of the formingmembers 144, and between the outermost forming members 144 and thecasting bed, to define the channels in which the concrete joists 124will be formed. In various example embodiments, methods of maintainingthe spacing may be employed to keep the forming members 144 in placeduring the pouring of the uncured concrete. The structural reinforcementcomponents 76 and lift hooks 116 may be placed as in FIGS. 11-14, andthe uncured concrete is poured over the forming members 144. In theexample embodiment illustrated in FIGS. 15-18, no intermediate beam orweb stiffener is included at a center of the panel 136, as the soffit140 will provide additional structural support for the panel 136.However, in various example embodiments of the present general inventiveconcept, one or more such web stiffeners may be provided. Variousexample embodiments of the present general inventive concept may employconnection components to assist the soffit 140 and the later pouredconcrete to adhere to one another. In various example embodiments of thepresent general inventive concept, the soffit layer 140 may be addedafter the upper layer has been formed by simply inverting the partiallypoured panel and adding the soffit layer 140 atop the panel 136 in acasting bed. In the example embodiment illustrated in FIGS. 15-18, thesoffit layer 140 is approximately 2 inches thick, but various exampleembodiments of the present general inventive concept may provide soffitsof various thicknesses. The soffit 140 may be finished to a desiredsurface as described in the previous example embodiments of the presentgeneral inventive concept.

Various example embodiments of the present general inventive concept mayprovide a method of forming the panel to be used as a floor, wall, orroof structure including positioning one or more forming members withina casting bed having a plurality of upright surfaces defining agenerally rectangular interior area, the one or more forming memberscomprising an insulating material extending along a length dimension ofthe one or more forming members to define a plurality ofrectangular-shaped channels in a parallel and spaced-apart relationship,placing uncured concrete within the casting bed and allowing theconcrete to cover the one or more forming members and substantially fillthe channels, and allowing the concrete to cure. The method may furtherinclude positioning a plurality of nailer strips within the casting bed,wherein the one or more forming members may include a plurality ofcomponents separated from one another on at least one side by one of thenailer strips. The one or more forming members may include a pluralityof nailer strips respectively provided adjacent to a bottom of aplurality of the channels. The nailer strips may be respectivelyprovided to every other one of the channels. The method may furtherinclude at least one channel provided across a width of the formingmember. The one or more forming members may include a layer ofinsulating material defining a plurality of integrally-formedrectangular protrusions extending along the length dimension of the oneor more forming members in a parallel and spaced-apart relationship toone another to define the plurality of rectangular-shaped channelstherebetween. The method may further include placing uncured concretewithin the casting bed before positioning the one or more formingmembers therein, and allowing the concrete to cure. The one or moreforming members may be completely encased in the concrete after theplacing of the uncured concrete within the casting bed and allowing theconcrete to cover the one or more forming members and substantially fillthe channels. A protrusion may be formed along an inner surface of eachof two lengthwise members of the casing bed such that a grout keyway isformed in lengthwise sides of the panel. The method may further includepositioning a plurality of reinforcing members within the casting bedprior to placing the uncured concrete over the forming member.

Various example embodiments of the present general inventive concept mayprovide a panel to be used as a floor, wall, or roof structure, thepanel including a concrete portion including a face portion and aplurality of joists extending inwardly from the face portion, and aplurality of insulating portions configured between each adjacent pairof the joists. The insulating portions may be configured to extendfurther from the face portion than the joists. The panel may furtherinclude a plurality of nailing strips provided respectively at ends ofat least a plurality of the joists. Each of the insulating portions maybe integrally formed with at least one adjacent insulating portion. Theconcrete portion may further include a back portion contacting ends ofthe joists opposite the face portion such that each of the insulatingportions provided between the joists is completely surrounded byconcrete.

It is noted that the simplified diagrams and drawings included in thepresent application do not illustrate all the various connections andassemblies of the various components, however, those skilled in the artwill understand how to implement such connections and assemblies, basedon the illustrated components, figures, and descriptions providedherein. Numerous variations, modification, and additional embodimentsare possible, and, accordingly, all such variations, modifications, andembodiments are to be regarded as being within the spirit and scope ofthe present general inventive concept. Furthermore, while the presentinvention has been illustrated by description of several embodiments andwhile the illustrative embodiments have been described in detail, it isnot the intention of the applicant to restrict or in any way limit thescope of the appended claims to such detail. Additional modificationswill readily appear to those skilled in the art. The invention in itsbroader aspects is therefore not limited to the specific details,representative apparatus and methods, and illustrative examples shownand described. Accordingly, departures may be made from such detailswithout departing from the spirit or scope of applicant's generalinventive concept.

The invention claimed is:
 1. A method of forming a panel to be used as afloor, wall, or roof structure, the method comprising: positioning oneor more forming members within a casting bed having a plurality ofupright surfaces defining a generally rectangular interior area, the oneor more forming members comprising an insulating material extendingalong a length dimension of the one or more forming members to define aplurality of rectangular-shaped channels in a parallel and spaced-apartrelationship, and at least one cross channel intersecting the pluralityof channels along a length thereof; placing uncured concrete within thecasting bed and allowing the concrete to cover the one or more formingmembers and substantially fill the channels; and allowing the concreteto cure.
 2. The method of claim 1, further comprising positioning aplurality of nailer strips within the casting bed, wherein the one ormore forming members comprise a plurality of components separated fromone another on at least one side by one of the nailer strips.
 3. Themethod of claim 1, wherein the one or more forming members include aplurality of nailer strips respectively provided adjacent to a bottom ofa plurality of the channels.
 4. The method of claim 3, wherein thenailer strips are respectively provided to every other one of thechannels.
 5. The method of claim 1, wherein the at least one crosschannel is configured to intersect a mid-point of the plurality ofchannels.
 6. The method of claim 1, wherein the one or more formingmembers includes a layer of insulating material defining a plurality ofintegrally-formed rectangular protrusions extending along the lengthdimension of the one or more forming members in a parallel andspaced-apart relationship to one another to define the plurality ofrectangular-shaped channels therebetween.
 7. The method of claim 1,further comprising placing uncured concrete within the casting bedbefore positioning the one or more forming members therein; and allowingthe concrete to cure.
 8. The method of claim 7, wherein the one or moreforming members are completely encased in the concrete after the placingof the uncured concrete within the casting bed and allowing the concreteto cover the one or more forming members and substantially fill thechannels.
 9. The method of claim 1, wherein a protrusion is formed alongan inner surface of each of two lengthwise members of the casting bedsuch that a grout keyway is formed in lengthwise sides of the panel. 10.The method of claim 1, further comprising positioning a plurality ofreinforcing members within the casting bed prior to placing the uncuredconcrete over the forming member.
 11. A method of forming a panel to beused as a floor, wall, or roof structure, the method comprising:positioning one or more forming members within a casting bed having aplurality of upright surfaces defining a generally rectangular interiorarea, the one or more forming members comprising an insulating materialextending along a length dimension of the one or more forming members todefine a plurality of rectangular-shaped channels in a parallel andspaced-apart relationship, wherein the one or more forming membersinclude a plurality of nailer strips respectively provided adjacent to abottom of a plurality of the channels; placing uncured concrete withinthe casting bed and allowing the concrete to cover the one or moreforming members and substantially fill the channels; and allowing theconcrete to cure.
 12. A method of forming a panel to be used as a floor,wall, or roof structure, the method comprising: positioning one or moreforming members within a casting bed having a plurality of uprightsurfaces defining a generally rectangular interior area, the one or moreforming members comprising an insulating material extending along alength dimension of the one or more forming members to define aplurality of rectangular-shaped channels in a parallel and spaced-apartrelationship, and at least one cross channel intersecting the pluralityof channels along a length thereof; positioning a plurality of nailerstrips within the casting bed, wherein the one or more forming memberscomprise a plurality of components separated from one another on atleast one side by one of the nailer strips; placing uncured concretewithin the casting bed and allowing the concrete to cover the one ormore forming members and substantially fill the channels; and allowingthe concrete to cure.